Manufacture a Weight Hanger to Support a 15 kg Load.

Manufacturing Processes Lab Project Report

Bachelor of Science
Mechanical Engineering Department

Muhammad Faizan Zafar Bme#143036

Faizan Basharat Bme#143046
Raja Arslan Shamshad Bme#143039
Saad Bin Sarfraz Bme#143004

Submitted to:
Mr. Noman Tahir
Department of Mechanical Engineering
CUST, Islamabad

7 June, 2017

i
 Abstract

According to the project statement that has been assigned to our group was to manufacture a weight
hanger to support 15 kg load with given maximum geometric constraints that total length of
hanger= 250 mm and diameter of hanger would be= 20 mm. we used iron for manufacturing of
hanger because its provide excellent machinability, allowing for high speeds and feeds. We
selected hollow rod as compared to solid rod the reason is when hanger is loaded, the hollow rod
has more material at the ends to bear the high compressive and tensile stresses and is thus stronger
than the solid rod. We used assembly method for manufacturing of hanger. On Lathe machine
facing and turning operation has used in order to reduce length and diameter of rod to get desired
dimensions. We used Drilling machine to drill a hole in base plate for welding operation. We
selected electrical arc welding for permanent joining of rod and base metal. After joining process
of hanger, final testing has been conducted by using ansys and applying manual 20 kg load.
According to our test this weight hanger safely support 15+5 kg with +5% tolerances.

2|Page
Contents
1.0 Introduction ............................................................................................................................................ 5
2.0 Scope of Project ...................................................................................................................................... 5
3.0 Methodology........................................................................................................................................... 5
3.1 Selection of Material ........................................................................................................................... 5
3.2 Selection of Hollow hanger VS solid hanger ....................................................................................... 5
3.2.1 Calculating solid and hollow rod Moment of Area .......................................................................... 6
3.3 Technical Aspects ................................................................................................................................ 7
3.3.1 Process of Manufacturing Flow Chart .......................................................................................... 7
4.0 Weight Hanger Final Dimension ............................................................................................................. 7
5.0 Financial Aspects ..................................................................................................................................... 8
6.0 Results and discussion ............................................................................................................................ 8
7.0 Conclusion ............................................................................................................................................... 8
8.0 Ansys Results........................................................................................................................................... 9
9.0 Appendices ............................................................................................................................................ 11

3|Page
 List of Figures
Figure 1 Punching operation ................................................................................................................... 11
Figure 2 20 kg weight for testing of hanger ............................................................................................ 11
Figure 3 Base Plate ................................................................................................................................. 12
Figure 4 Drilling ..................................................................................................................................... 12
Figure 5 Welding operation ..................................................................................................................... 13
Figure 6 Grinding..................................................................................................................................... 13
Figure 7 Forging ...................................................................................................................................... 14
Figure 8 Finished Product ........................................................................................................................ 14

4|Page
1.0 Introduction
Weight hanger is used to quickly create any desired amount of mass. These hangers are also in
student lab classes, to teach physics and other sciences. Hangers are used to easily apply load in
several equipment to demonstrate different concepts in labs. Hangers may be of different designs
and different materials can be used to manufacture them, with the help of different processes.

2.0 Scope of Project

This Scope of this project is to introduce the principles of design for manufacturing. This is an
open-ended project in order to examine and take decision about selection of the manufacturing
operations including machining, casting, forging, welding, finishing, heat treating, and assembly
to complete weight hanger that support 15 kg load. Including understands manufacturing
operations, including their capabilities, limitations and how the designer affects manufacturing
cost.

3.0 Methodology
3.1 Selection of Material
We selected iron as raw material for manufacturing of a weight hanger due to following
benefits:
Good strength to weight ratio.
Typically, lower cost than competing materials and relatively low cost per
unit of strength than other materials.
Excellent machinability, allowing for high speeds and feeds. Rapid
transition from design to finished product.
Tensile Strength= 50 kpsi.

3.2 Selection of Hollow hanger VS solid hanger

The hollow hanger has more material at the ends to bear the high
compressive and tensile stresses and is thus stronger than the solid hanger.
The second moment of area, also known as the area moment of inertia is a
property of a cross section that can be used to predict the resistance to
deflection.
The deflection of a beam under load depends not only on the load, but
also on the geometry of the beam's cross-section, more resistance to
bending with higher moment of area.

5|Page
3.2.1 Calculating solid and hollow rod Moment of Area

di=10.5mm

d= 5mm do=12.53mm
(a) Solid rod (b) Hollow rod

Solid rod
Area= *(d/2)2= 19.2 mm2

Is= *d4/64=30.66 mm4

Hollow Rod

Area= *(do/2) -*(di/2) = 36.69 mm2

Ih= *(d04-di4)/64=612 mm4

so compares area moment of inertia for the hollow vs. the solid beam
Ih/Is= 20.34

The hollow tube area moment of inertia is approximately 20 times that

of a solid rod of the same cross sectional area (weight).
We selected hollow rod as compared to solid rod the reason is when
hanger is loaded, the hollow rod has more material at the ends to bear
the high compressive and tensile stresses and is thus stronger than the
solid rod.

6|Page
 3.3 Technical Aspects
3.3.1 Process of Manufacturing Flow Chart

Lathe Operation

Drilling Operation

Forging Operation

Preparation of material using sanding operation

Arc Welding (Permanent Joining)

Inspection of Weight Hanger

Finishing Operation

4.0 Weight Hanger Final Dimension

S.N. Description Dimension (mm)

1. Rod Inner Diameter (di) 10
2. Rod Outer Diameter (do) 13
3. Thickness of pipe(t) 0.125
4. Base Plate Thickness (t) 3
5. Base Plate Diameter 39.0
6. Ring Diameter 52.1
7. Hole diameter(drilled) 8
6. Length of rod 217

All dimensions are with tolerance of +0.1mm.

7|Page
5.0 Financial Aspects
Total project cost is given below

S.N. Description Price (Rs )

1. Material Cost (Iron) 300/-
2. Product Finishing Cost 200/-

6.0 Results and discussion

Ansys software is used for the analysis of the hanger. Following results are obtained

Base Hook
Total deflection(m) 3.0077exp(-7) 3.3419exp(-8)
Equivalent 220.43 17288
stress(pascals)
Equivalent Elastic 1.2533exp(-8) 1.591exp(-7)
strain(m/m)

Maximum value of total deflection is at base and minimum value is at hook. This shows base is
critical for failure of hanger. Maximum value of equivalent stress is at hook because when load is
applied at base, internal resistance due to applied load is produced in hook. Also equivalent elastic
strain value is maximum at hook because strain generated due to stresses produced in hanger.

7.0 Conclusion

From the results obtained, we concluded that the base is critical for failure of hanger due to
maximum value of deflection at base. Our hanger can bear weight up to 20kg.Cast iron is porous
in nature so that it can corrode, in view of this we have sprayed cast iron hanger to prevent
corrosion which results in damage of welded joints. Different designs can be used to manufacture
hanger; we have chosen this unique design because it can ban more load due to hollow rod.

8|Page
8.0 Ansys Results

9|Page
10 | P a g e
9.0 Appendices

Figure 1 Punching operation

Figure 2 20 kg weight for testing of hanger

11 | P a g e
Figure 3 Base Plate

Figure 4 Drilling

12 | P a g e
Figure 5 Welding operation

Figure 6 Grinding

13 | P a g e
 Figure 7 Forging

Figure 8 Finished Product

14 | P a g e